U.S. patent number 10,694,814 [Application Number 15/982,749] was granted by the patent office on 2020-06-30 for cushioning article with tensile component and method of manufacturing a cushioning article.
This patent grant is currently assigned to NIKE, Inc.. The grantee listed for this patent is NIKE, Inc.. Invention is credited to Page J. Bailey, Jeremy L. Connell, Jason R. Meeker.
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United States Patent |
10,694,814 |
Bailey , et al. |
June 30, 2020 |
Cushioning article with tensile component and method of
manufacturing a cushioning article
Abstract
A cushioning article comprises a first and a second polymeric
sheet bonded to one another and enclosing an interior cavity. The
polymeric sheets retain a gas in the interior cavity. A tensile
component disposed in the interior cavity includes a first tensile
layer, a second tensile layer, and a plurality of tethers spanning
the interior cavity and connecting the first tensile layer to the
second tensile layer. An inwardly-protruding bond joins the first
polymeric sheet to the first tensile layer, protrudes inward from
the first polymeric sheet toward the second polymeric sheet, and
partially traverses the plurality of tethers. The first polymeric
sheet is displaced from the first tensile layer adjacent to the
inwardly-protruding bond by the gas. A method of manufacturing a
cushioning article is disclosed.
Inventors: |
Bailey; Page J. (Portland,
OR), Connell; Jeremy L. (Hillsboro, OR), Meeker; Jason
R. (Hillsboro, OR) |
Applicant: |
Name |
City |
State |
Country |
Type |
NIKE, Inc. |
Beaverton |
OR |
US |
|
|
Assignee: |
NIKE, Inc. (Beaverton,
OR)
|
Family
ID: |
62620954 |
Appl.
No.: |
15/982,749 |
Filed: |
May 17, 2018 |
Prior Publication Data
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Document
Identifier |
Publication Date |
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US 20180332925 A1 |
Nov 22, 2018 |
|
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
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62508044 |
May 18, 2017 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A43B
9/12 (20130101); B32B 27/40 (20130101); A43B
17/006 (20130101); B29D 35/122 (20130101); A43B
13/04 (20130101); B29D 35/142 (20130101); B32B
7/05 (20190101); A43B 1/0009 (20130101); B32B
3/12 (20130101); B32B 27/08 (20130101); A43B
13/20 (20130101); B32B 27/306 (20130101); A43B
13/181 (20130101); B32B 2437/02 (20130101); B29K
2023/086 (20130101); B32B 2307/7242 (20130101); B29K
2995/0067 (20130101); B29K 2075/00 (20130101) |
Current International
Class: |
A43B
13/20 (20060101); A43B 13/04 (20060101); A43B
13/18 (20060101); A43B 9/12 (20060101); B32B
3/12 (20060101); A43B 17/00 (20060101); B29D
35/12 (20100101); B32B 7/05 (20190101); A43B
1/00 (20060101); B29D 35/14 (20100101); B32B
27/40 (20060101); B32B 27/30 (20060101); B32B
27/08 (20060101) |
Field of
Search: |
;36/29 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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9809546 |
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Mar 1998 |
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WO |
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2010057207 |
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May 2010 |
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WO |
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2015145329 |
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Oct 2015 |
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WO |
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2017053654 |
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Mar 2017 |
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WO |
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Primary Examiner: Bays; Marie D
Attorney, Agent or Firm: Quinn IP Law
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional
Application No. 62/508,044 filed May 18, 2017, which is hereby
incorporated by reference in its entirety.
Claims
What is claimed is:
1. A cushioning article comprising: a bladder enclosing an interior
cavity and retaining a gas in the interior cavity; a tensile
component disposed in the interior cavity and including tensile
layers and a plurality of tethers connecting the tensile layers,
the tensile layers connected to an inner surface of the bladder at
a plurality of bonds such that the tethers span across the interior
cavity; the plurality of bonds arranged in closed shapes
surrounding domed portions of the bladder; activated anti-weld
material disposed on selected areas of the tensile component; the
plurality of bonds bonding the inner surface of the bladder to the
tensile component, the domed portions of the bladder unbonded to
the tensile component at the selected areas on which the activated
anti-weld material is disposed, the domed portions displaced from
the tensile component by the gas; and wherein each of the plurality
of bonds protrudes inward into the interior cavity and partially
traverses the plurality of tethers such that the bladder is
narrowed at the plurality of bonds.
2. The cushioning article of claim 1, wherein the bladder comprises
a first polymeric sheet and a second polymeric sheet bonded to one
another at a peripheral flange and enclosing the interior cavity;
and wherein the tensile layers include a first tensile layer
connected to the first polymeric sheet and a second tensile layer
connected to the second polymeric sheet, at least one of the first
polymeric sheet and the second polymeric sheet including the domed
portions.
3. The cushioning article of claim 1, wherein when an inflation
pressure of the gas in the interior cavity is sufficient to tension
the plurality of tethers, the plurality of bonds defines grooves at
an outer surface of the bladder such that the cushioning article is
articulated along the grooves.
4. The cushioning article of claim 1, wherein the plurality of
bonds is a first plurality of bonds in a first region of the
bladder, and the bladder has a second plurality of bonds arranged
in closed shapes in a second region of the bladder, and portions of
the bladder surrounded by the closed shapes in the second region
are bonded to the tensile component.
5. The cushioning article of claim 4, wherein the cushioning
article is a sole component of an article of footwear, the first
region is on a distal side of the bladder, and the second region is
on a proximal side of the bladder.
6. The cushioning article of claim 4, wherein the cushioning
article is a sole component of an article of footwear, and the
first region and the second region are both on a distal side of the
bladder or are both on a proximal side of the bladder.
7. The cushioning article of claim 1, wherein the plurality of
bonds are a first plurality of bonds in a first region of the
bladder, and the bladder has a second plurality of bonds arranged
in closed shapes in a second region of the bladder, and portions of
the bladder surrounded by the closed shapes in the second region
are unbonded to the tensile component at the selected areas on
which the activated anti-weld material is disposed and form domed
portions that are displaced from the tensile component by the
gas.
8. A cushioning article for a footwear sole structure, comprising:
a first polymeric sheet and a second polymeric sheet bonded to one
another and enclosing an interior cavity, the first polymeric sheet
and the second polymeric sheet retaining a gas in the interior
cavity; a tensile component disposed in the interior cavity, the
tensile component including a first tensile layer, a second tensile
layer, and a plurality of tethers spanning the interior cavity from
the first tensile layer to the second tensile layer and connecting
the first tensile layer to the second tensile layer; a plurality of
inwardly-protruding bonds that join the first polymeric sheet to
the first tensile layer, protrude inward from the first polymeric
sheet toward the second polymeric sheet, and partially traverse the
plurality of tethers; wherein the inwardly-protruding bonds are
linear bonds arranged in closed polygonal shapes surrounding domed
portions of the first polymeric sheet at which the first polymeric
sheet is displaced from the first tensile layer by the gas; wherein
the inwardly-protruding bonds are spaced apart from the second
polymeric sheet such that the interior cavity is narrowed at the
inwardly-protruding bonds; and wherein the closed polygonal shapes
of the inwardly-protruding bonds surrounding three consecutive
domed portions are arranged so that each has an inwardly-protruding
bond aligned with a flexion axis of the footwear sole
structure.
9. The cushioning article of claim 8, wherein a portion of the
interior cavity at a first side of each inwardly-protruding bond is
in fluid communication with a portion of the interior cavity at a
second side of the inwardly-protruding bond, the second side
opposite of the first side.
10. The cushioning article of claim 8, wherein: the first tensile
layer is spaced apart from the second tensile layer by a first
distance at the domed portions; the inwardly-protruding bonds are
spaced apart from the second tensile layer by a second distance;
and the second distance is between 50 percent and 80 percent of the
first distance.
11. The cushioning article of claim 8, wherein: the plurality of
tethers includes tethers aligned with the inwardly-protruding bonds
and tethers displaced from the inwardly-protruding bonds; and the
tethers aligned with the inwardly-protruding bonds are shorter,
thicker, or both shorter and thicker than the tethers displaced
from the inwardly-protruding bonds.
12. The cushioning article of claim 8, wherein the flexion axis
extends transversely in a forefoot region of the cushioning
article.
13. The cushioning article of claim 8, wherein the flexion axis
extends in a heel region of the cushioning article.
14. The cushioning article of claim 8, wherein the closed polygonal
shapes of the inwardly-protruding bonds surrounding the three
consecutive domed portions are pentagons.
15. The cushioning article of claim 8, wherein the closed polygonal
shapes of the inwardly-protruding bonds surrounding three
additional consecutive domed portions are arranged so that each has
an inwardly-protruding bond aligned with the flexion axis of the
footwear sole structure, the flexion axis extending between the
three consecutive domed portions and the three additional
consecutive domed portions.
16. The cushioning article of claim 15, wherein the closed
polygonal shapes of the inwardly-protruding bonds surrounding the
three consecutive domed portions and the three additional
consecutive domed portions are pentagons.
Description
TECHNICAL FIELD
The present teachings generally include a cushioning article having
a tensile component, and a method of manufacturing the cushioning
article with an inwardly-protruding bond.
BACKGROUND
A cushioning article, such as a sole component of an article of
footwear, is typically configured to provide cushioning, motion
control, and/or resilience. Some cushioning articles utilize a
sealed interior cavity filled with a gas that resiliently reacts a
compressive load. A tensile component may be disposed in the
interior cavity, and may limit the outward expansion of the
cushioning article.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration in plan view of a cushioning
article in accordance with the present teachings.
FIG. 2 is a schematic illustration in bottom view of the cushioning
article of FIG. 1.
FIG. 3 is a schematic illustration in cross-sectional view of the
cushioning article of FIG. 1, taken at lines 3-3 in FIG. 1.
FIG. 4 is a schematic illustration in close-up cross-sectional view
of a portion of the cushioning article of FIG. 3.
FIG. 5 is a schematic illustration in close-up cross-sectional view
of the cushioning article of FIG. 4 under loading in a first stage
of compression.
FIG. 6 is a schematic illustration in close-up cross-sectional view
of the cushioning article of FIG. 4 under loading in a second stage
of compression.
FIG. 7 is a schematic illustration in close-up cross-sectional view
of the cushioning article of FIG. 4 under loading in a third stage
of compression.
FIG. 8 is a schematic illustration in cross-sectional view of the
cushioning article of FIG. 1, taken at lines 8-8 in FIG. 1.
FIG. 9 is a schematic illustration in medial side view of an
article of footwear with a sole structure that includes the
cushioning article of FIG. 1, indicated in hidden lines.
FIG. 10 is a schematic illustration in plan view of a cushioning
article in accordance with an alternative aspect of the present
teachings.
FIG. 11 is a schematic illustration in bottom view of the
cushioning article of FIG. 10.
FIG. 12 is a schematic illustration in fragmentary cross-sectional
view of the cushioning article of FIG. 10, taken at lines 12-12 in
FIG. 10.
FIG. 13 is a schematic illustration in medial side view of the
cushioning article of FIG. 1.
FIG. 14 is a schematic illustration in medial side view of the
cushioning article of FIG. 10.
FIG. 15 is a schematic illustration in exploded cross-sectional
view of components of the cushioning article of FIG. 1 and a mold
used in manufacturing the cushioning article.
FIG. 16 is a schematic illustration of the components of the
cushioning article of FIG. 1 in the mold of FIG. 16, with the mold
in a closed position.
FIG. 17 is a schematic perspective illustration of a mold portion
for manufacturing cushioning components.
FIG. 18 is a schematic perspective illustration of the mold portion
of FIG. 17 with a first mold insert secured to the mold
portion.
FIG. 19 is a schematic perspective illustration of a second mold
insert for use with the mold portion of FIG. 17.
FIG. 20 is a flow chart of a method of manufacturing a cushioning
article.
FIG. 21 is a schematic illustration in plan view of a cushioning
article in accordance with an alternative aspect of the present
teachings.
FIG. 22 is a schematic illustration in bottom view of the
cushioning article of FIG. 21.
FIG. 23 is a schematic illustration in cross-sectional view of the
cushioning article of FIG. 21, taken at lines 23-23 in FIG. 21.
FIG. 24 is a schematic illustration in medial side view of the
cushioning article of FIG. 21.
DESCRIPTION
A cushioning article comprises a bladder enclosing an interior
cavity and retaining a gas in the interior cavity. A tensile
component is disposed in the interior cavity and includes tensile
layers and a plurality of tethers connecting the tensile layers.
The tensile layers are connected to an inner surface of the bladder
such that the tethers span across the interior cavity. The bladder
has a plurality of bonds arranged in closed shapes surrounding
domed portions of the bladder. The plurality of bonds bond the
inner surface of the bladder to the tensile component. The domed
portions of the bladder are unbonded to the tensile component and
are therefore displaced from the tensile component by the gas.
In one or more embodiments, the bladder comprises a first polymeric
sheet and a second polymeric sheet bonded to one another at a
peripheral flange and enclosing the interior cavity. The tensile
layers include a first tensile layer connected to the first
polymeric sheet and a second tensile layer connected to the second
polymeric sheet. At least one of the first polymeric sheet and the
second polymeric sheet includes the domed portions.
The plurality of bonds may protrude inward into the interior cavity
and partially traverse the plurality of tethers such that the
bladder is narrowed at the plurality of bonds. When an inflation
pressure of the gas in the interior cavity is sufficient to tension
the plurality of tethers, the plurality of bonds defines grooves at
an outer surface of the bladder such that the cushioning article is
articulated along the grooves.
The plurality of bonds may be a first plurality of bonds in a first
region of the bladder, and the bladder may have a second plurality
of bonds arranged in closed shapes in a second region of the
bladder. Portions of the bladder surrounded by the closed shapes in
the second region may be bonded to the tensile component.
The cushioning article may be for a variety of applications, such
as but not limited to a sole component of an article of footwear.
In such an embodiment, the first region may be on a distal side of
the bladder (i.e., a ground contact side), and the second region
may be on a proximal side of the bladder (i.e., a foot-facing
side). In other embodiments, the first region and the second region
are both on a distal side of the bladder or are both on a proximal
side of the bladder. In still other embodiments, the plurality of
bonds are a first plurality of bonds in a first region of the
bladder, and the bladder has a second plurality of bonds arranged
in closed shapes in a second region of the bladder. Portions of the
bladder surrounded by the closed shapes in the second region are
unbonded to the tensile component and form domed portions that are
displaced from the tensile component by the gas. For example, both
the proximal side and the distal side of the cushioning article may
have the domed portions.
A cushioning article comprises a first polymeric sheet and a second
polymeric sheet bonded to one another and enclosing an interior
cavity. The first polymeric sheet and the second polymeric sheet
retain a gas in the interior cavity. A tensile component is
disposed in the interior cavity. The tensile component includes a
first tensile layer, a second tensile layer, and a plurality of
tethers spanning the interior cavity from the first tensile layer
to the second tensile layer and connecting the first tensile layer
to the second tensile layer. An inwardly-protruding bond joins the
first polymeric sheet to the first tensile layer, protrudes inward
from the first polymeric sheet toward the second polymeric sheet,
and partially traverses the plurality of tethers. The first
polymeric sheet is displaced from the first tensile layer adjacent
to the inwardly-protruding bond by the gas. The inwardly-protruding
bond is spaced apart from the second polymeric sheet such that the
interior cavity is narrowed at the inwardly-protruding bond and the
gas in the interior cavity fluidly communicates across the
inwardly-protruding bond. Accordingly, the consistency and
responsiveness of tethers in returning the interior cavity to its
original shape following a dynamic compressive load is combined
with staged cushioning, and the flexibility of an articulated
cushioning component, with articulation occurring in alignment with
the tethers traversed by the inwardly-protruding bond.
In one or more embodiments, the cushioning article is a sole
component for an article of footwear, and the inwardly-protruding
bond establishes a flexion axis of the sole component. Accordingly,
the cushioning component may be articulated at the
inwardly-protruding bond, and the flexion axes may be aligned with
desired flexion regions of a foot, for example, such as the
metatarsal-phalangeal joints.
In one or more embodiments, a portion of the interior cavity at a
first side of the inwardly-protruding bond is in fluid
communication with a portion of the interior cavity at a second
side of the inwardly-protruding bond, with the second side opposite
of the first side. The gas in the interior cavity can thus be
displaced across the inwardly-protruding bond, such as during a
foot strike or foot roll of an article of footwear when the
cushioning article is included in a sole structure.
In one or more embodiments, an inflation pressure of the gas in the
interior cavity is sufficient to tension the plurality of tethers
at the inwardly-protruding bond, and the inwardly-protruding bond
defines a groove at an outer surface of the first polymeric sheet
such that the cushioning article is divided into a first article
portion on one side of the groove and a second article portion on
the other side of the groove, and the first article portion is
articulated relative to the second article portion along the
groove.
In one or more embodiments, the first tensile layer is spaced apart
from the second tensile layer by a first distance at a location
adjacent to the inwardly-protruding bond, and the
inwardly-protruding bond is spaced apart from the second tensile
layer by a second distance. The second distance is between 50
percent and 80 percent of the first distance. Narrowing of the
interior cavity by this ratio may provide an optimal range of
articulation that contributes to flexibility of the cushioning
article.
Because the inwardly-protruding bond at least partially traverses
the plurality of tethers, in one or more embodiments, the plurality
of tethers includes tethers aligned with the inwardly-protruding
bond and tethers displaced from the inwardly-protruding bond. The
tethers aligned with the inwardly-protruding bond are shorter,
thicker, or both shorter and thicker than the tethers displaced
from the inwardly-protruding bond. The tethers are originally all
of the same length and width prior to manufacturing the cushioning
article and establishing the inwardly-protruding bond. The
deformation of the tethers that occurs during manufacturing at the
inwardly-protruding bond contributes to the articulation and
flexibility of the cushioning article.
In one or more embodiments, the inwardly-protruding bond defines a
closed shape surrounding a portion of the first polymeric sheet
displaced from the first tensile layer such that the portion of the
first polymeric sheet has a domed surface extending away from the
first tensile layer.
In some embodiments, the second polymeric sheet is recessed inward
toward the inwardly-protruding bond of the first polymeric sheet
when the interior cavity is inflated. In other embodiments, the
second polymeric sheet also has inwardly-protruding bonds.
In some embodiments, the inwardly-protruding bond may be a first
inwardly-protruding bond, the portion of the first polymeric sheet
surrounded by the closed shape is a first portion of the first
polymeric sheet in a first region of the first polymeric sheet, an
inner surface of a second portion of the first polymeric sheet in a
second region of the first polymeric sheet spaced apart from the
first region is bonded to an outer surface of the first tensile
layer; and the cushioning article may further comprise a second
inwardly-protruding bond that joins the first polymeric sheet to
the first tensile layer and protrudes from the first polymeric
sheet toward the second polymeric sheet in the second region and
partially traverses the tensile component. The second
inwardly-protruding bond may be spaced apart from the second
polymeric sheet such that the interior cavity is narrowed at the
second inwardly-protruding bond and the gas in the interior cavity
fluidly communicates across the second inwardly-protruding
bond.
A method of manufacturing a cushioning article comprises disposing
anti-weld material on at least one of an inner surface of a first
polymeric sheet and an outer surface of a first tensile layer of a
tensile component. The tensile component includes the first tensile
layer, a second tensile layer, and a plurality of tethers
connecting the first tensile layer to the second tensile layer. The
method further comprises conforming the first polymeric sheet and a
second polymeric sheet to components of a mold. Conforming the
first polymeric sheet in this manner depresses the first polymeric
sheet toward the second polymeric sheet at protrusions of the mold
arranged in closed shapes and with the protrusion directly outward
of the plurality of tethers. The method further comprises thermally
bonding the first tensile layer to the first polymeric sheet and
the second tensile layer to the second polymeric sheet opposite the
first tensile layer. Thermally bonding the tensile layers to the
polymeric sheets in this manner produces a plurality of bonds at
the protrusion that joins the first polymeric sheet to the first
tensile layer and partially traverses the plurality of tethers. The
plurality of bonds protrude toward the second polymeric sheet and
are spaced apart from the second tensile layer and the second
polymeric sheet. The first polymeric sheet is separated from the
first tensile layer adjacent to the inwardly-protruding bonds due
to the anti-weld material such that portions of the first polymeric
sheet surrounded by the plurality of bonds forming the closed
shapes are displaceable from the first tensile layer. For example,
when inflated, a portion of the first polymeric surrounded by bonds
forming a closed shape forms a domed surface.
In one or more embodiments, the method further comprises bonding
the first polymeric sheet to the second polymeric sheet at a
peripheral bond such that the first polymeric sheet and the second
polymeric sheet at least partially enclose an interior cavity
containing the tensile component. The plurality of tethers span
across the interior cavity from the first tensile layer to the
second tensile layer. The plurality of bonds protrudes inward such
that the interior cavity is narrowed at the inwardly-protruding
bond.
In one or more embodiments, the method further comprises inflating
and sealing the interior cavity. Inflating the interior cavity in
this manner lifts the portions of the first polymeric sheet
surrounded by the closed shapes away from the tensile component to
form the domed portions, and tensions the plurality of tethers at
the plurality of bonds to creates a plurality of grooves in an
outer surface of the first polymeric sheet at the plurality of
bonds, thereby articulating the cushioning article. For example,
the cushioning article may be a sole component for an article of
footwear, and the groove may establish a flexion axis of the sole
component.
In one or more embodiments, the components of the mold include a
first mold portion and a second mold portion. At least one of the
first mold portion and the second mold portion is translatable
relative to the other of the first mold portion and the second mold
portion between an open position and a closed position. Bonding the
first polymeric sheet and the second polymeric sheet at the
peripheral bond includes compressing the first polymeric sheet and
the second polymeric sheet between the first mold portion and the
second mold portion in the closed position.
In one or more embodiments, the mold component having the plurality
of protrusions is one of the first mold portion and the second mold
portion. Alternatively, in other embodiments, the mold component
having the plurality of protrusions is a mold insert. This enables
the bond pattern of the cushioning articles manufactured according
to the method to be easily changed by changing the mold insert to a
different mold insert that has a different pattern of protrusions.
For example, the method may further comprise, prior to conforming
the first polymeric sheet and the second polymeric sheets to
components of the mold, securing a mold insert to a mold portion of
the mold, and wherein the mold component having the plurality of
protrusions is the mold insert. In some embodiments, the mold
insert is a first mold insert, the mold portion is a first mold
portion, the plurality of bonds is a first plurality of bonds, and
the method further comprises securing a second mold insert to a
second mold portion of the mold, wherein the second mold insert has
a second plurality of protrusions directly opposite the first
plurality of protrusions and outward of the plurality of tethers.
In such an embodiment, conforming the first and second polymeric
sheets and thermally bonding the first tensile layer to the first
polymeric sheet and the second tensile layer to the second
polymeric sheet produces a second plurality of bonds at the second
plurality of protrusions partially traversing the tensile component
directly opposite the first plurality of bonds. The second
plurality of bonds protrudes toward the first plurality of bonds
and the first polymeric sheet, and is spaced apart from the first
plurality of bonds, the first tensile layer, and the first
polymeric sheet.
In one or more embodiments, the cushioning article is a first
cushioning article, and the method further comprises manufacturing
a second cushioning article by removing the mold insert from the
mold portion, and securing a second mold insert having a second
plurality of protrusions to the mold portion. The second plurality
of protrusions is shaped, dimensioned or positioned differently
than the first plurality of protrusions. The method further
comprises conforming a subsequent first polymeric sheet and a
subsequent second polymeric sheet to the second mold insert and to
another one of the components of the mold, respectively, with a
subsequent tensile component between the subsequent first polymeric
sheet and the subsequent second polymeric sheet. Conforming the
subsequent first and second polymeric sheets in this manner
depresses the subsequent first polymeric sheet toward the
subsequent second polymeric sheet at the second plurality of
protrusions, with the second plurality of protrusions directly
outward of the subsequent tensile component, thereby producing a
second plurality of bonds at the second plurality of protrusions
partially traversing the subsequent tensile component. The mold
thus provides the second cushioning article with a different bond
pattern than the first cushioning article due to the second mold
insert.
In one or more embodiments, conforming the first polymeric sheet
and the second polymeric sheet to components of the mold is by
vacuum, compression, or both. Additionally, in one or more
embodiments, thermal bonding of the first tensile layer to the
first polymeric sheet and the second tensile layer to the second
polymeric sheet includes at least one of heating the first
polymeric sheet and the second polymeric sheet, heating the mold
components, or radio frequency welding.
The above features and advantages and other features and advantages
of the present teachings are readily apparent from the following
detailed description of the modes for carrying out the present
teachings when taken in connection with the accompanying
drawings.
Referring to the drawings, wherein like reference numbers refer to
like components throughout the views, FIG. 1 shows a cushioning
article 10 that may be manufactured according to a method 210 of
FIG. 20 and has features that provide a desirable combination of
cushioning and flexibility. The cushioning article 10 is shown and
described as a cushioning article used in a sole structure 12 of an
article of footwear 14, shown in FIG. 9. The cushioning article 10
is a full length cushioning article for a sole structure 12, as it
has a forefoot region 17A, a midfoot region 17B, and a heel region
17C. The forefoot region 17A may be generally associated with the
toes and joints connecting the metatarsals with the phalanges. The
midfoot region 17B may be generally associated with the arch of a
foot. The heel region 17C may be generally associated with the heel
of a foot, including the calcaneus bone. The cushioning article 10
has a lateral side 19 and a medial side 21. In particular, the
lateral side 19 and the medial side 21 may be opposing sides of the
cushioning article 10, and may extend along the forefoot region
17A, the midfoot region 17B, and the heel region 17C. In the
embodiment of the cushioning article 10 shown in FIGS. 1 and 2, the
first polymeric sheet 16 establishes the proximal side of the
bladder 23 (i.e., the side closest to the foot when assembled in an
article of footwear). The second polymeric sheet 18 establishes the
distal side of the bladder 23 (i.e., the ground-facing side of the
bladder).
In FIG. 9, the cushioning article 10 is shown at least partially
encased in a foam sole layer 11, and together the cushioning
article 10 and sole layer 11 serve as a midsole of the sole
structure 12. An outsole, an insole, and other sole components may
also be included in the sole structure 12. The cushioning article
10 is thus a sole component. However, the cushioning article 10 or
other cushioning articles manufactured according to the method 210
may be used in other articles, such as athletic apparel, sports
equipment, furniture, and floor mats. For example, the cushioning
article may be for a backpack strap, a helmet cushion, a shin
guard, a baseball glove, a seat cushion, or a floor mat.
Referring to FIGS. 1-3, the cushioning article 10 includes a
bladder 23 having a first polymeric sheet 16 and a second polymeric
sheet 18 bonded to one another at a peripheral bond 20 to enclose
an interior cavity 22. When the sheets 16, 18 are bonded together
at the peripheral bond 20 and any inflation port 82 is sealed, the
first polymeric sheet 16 and the second polymeric sheet 18 retain a
fluid in the interior cavity 22. As used herein, a "fluid" filling
the interior cavity 22 may be a gas, such as air, nitrogen, another
gas, or a combination thereof.
The first and second polymeric sheets 16, 18 can be a variety of
polymeric materials that can resiliently retain a fluid such as
nitrogen, air, or another gas. Examples of polymeric materials for
the first and second polymeric sheets 16, 18 include thermoplastic
urethane, polyurethane, polyester, polyester polyurethane, and
polyether polyurethane. Moreover, the first and second polymeric
sheets 16, 18 can each be formed of layers of different materials
including polymeric materials. In one embodiment, each of the first
and second polymeric sheets 16, 18 is formed from thin films having
one or more thermoplastic polyurethane layers with one or more
barrier layers of a copolymer of ethylene and vinyl alcohol (EVOH)
that is impermeable to the pressurized fluid contained therein such
as a flexible microlayer membrane that includes alternating layers
of a gas barrier material and an elastomeric material, as disclosed
in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk et al. which are
incorporated by reference in their entireties. Alternatively, the
layers may include ethylene-vinyl alcohol copolymer, thermoplastic
polyurethane, and a regrind material of the ethylene-vinyl alcohol
copolymer and thermoplastic polyurethane. Additional suitable
materials for the first and second polymeric sheets 16, 18 are
disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy which
are incorporated by reference in their entireties. Further suitable
materials for the first and second polymeric sheets 16, 18 include
thermoplastic films containing a crystalline material, as disclosed
in U.S. Pat. Nos. 4,936,029 and 5,042,176 to Rudy, and polyurethane
including a polyester polyol, as disclosed in U.S. Pat. Nos.
6,013,340, 6,203,868, and 6,321,465 to Bonk et al. which are
incorporated by reference in their entireties. In selecting
materials for the cushioning article 10, engineering properties
such as tensile strength, stretch properties, fatigue
characteristics, dynamic modulus, and loss tangent can be
considered. For example, the thicknesses of the first and second
polymeric sheets 16, 18 used to form the cushioning article 10 can
be selected to provide these characteristics.
As best shown in FIG. 3, the cushioning article 10 includes a
tensile component 30 disposed in the interior cavity 22. The
tensile component 30 includes a first tensile layer 32, a second
tensile layer 34, and a plurality of tethers 36 spanning the
interior cavity 22 from the first tensile layer 32 to the second
tensile layer 34. The tethers 36 connect the first tensile layer 32
to the second tensile layer 34. Only some of the tethers 36 are
indicated with reference numbers in FIG. 3. The tethers 36 may also
be referred to as fabric tensile members or threads, and may be in
the form of drop threads that connect the first tensile layer 32
and the second tensile layer 34. The tensile component 30 may be
formed as a unitary, one-piece textile element having a spacer-knit
textile. It should be appreciated that the first tensile layer 32
and the second tensile layer 34 are permeable by the gas in the
interior cavity. As such, the interior cavity 22 extends through
the first tensile layer 32 and the second tensile layer 34, in
between and around the tethers 36, from the inner surface of the
first polymeric sheet 16 to the inner surface of the second
polymeric sheet 18. The tensile layers 32, 34 are not subjected to
outward forces by the gas in the interior cavity where the tensile
layers are not bonded to the first and second polymeric sheets 16,
18. Accordingly, tethers 36B that extend between the portions of
the tensile layer 32, 34 that are not bonded to the polymeric
sheets 16, 18 (e.g., the portions of the tensile layers 32, 34 that
are inward of the domed portions) may not be in tension. However,
tethers 36A that extend between the portions of the tensile layers
32, 34 bonded to the polymeric sheets 16, 18 (e.g., at
inwardly-protruding bonds 50) are subjected to tension under a
sufficiently inflation pressure of the interior cavity 22.
Anti-weld material 48 is applied to selected areas of the outer
surfaces 45, 47, respectively, of the first and second tensile
layers 32, 34 as best shown in FIG. 15. For example, anti-weld
material may be ink jet printed everywhere except at areas where
protrusions of mold components used during thermoforming of the
cushioning article 10 cause inwardly-protruding bonds 50 of the
first polymeric sheet 16 and the second polymeric sheet 18, as
further explained herein. The inwardly-protruding bonds 50 of the
first polymeric sheet 16 are also referred to as a first plurality
of bonds. Alternatively, anti-weld material may be applied even
where the bonds 50 are desired, if the anti-weld material is not
activated. The anti-weld material 48, if activated, prevents the
inner surfaces 42, 46 of the first and second polymeric sheets 16,
18 from bonding to the outer surfaces 45, 47 of the tensile
component 30 during the manufacturing method 210 described herein.
The first tensile layer 32 is bonded to an inner surface 42 of the
first polymeric sheet 16 at the inwardly-protruding bonds 50. The
second tensile layer 34 is bonded to an inner surface 46 of the
second polymeric sheet 18 at inwardly-protruding bonds 50 as best
shown in FIG. 3. The inwardly-protruding bonds 50 of the second
polymeric sheet 18 are also referred to as a second plurality of
bonds. The first plurality of bonds 50 are in a first region of the
bladder 23 (e.g., on the proximal side in each of the forefoot,
midfoot, and heel regions), and the second plurality of bonds 50
are in a second region of the bladder 23 (e.g., on the distal side
in each of the forefoot, midfoot, and heel regions).
The tethers 36 restrain separation of the first and second
polymeric sheets 16, 18 to the maximum separated positions shown in
FIG. 3 under a given inflation pressure of gas in the interior
cavity 22. The outward force of pressurized gas in the interior
cavity 22 on the inner surfaces 42, 46 of the first and second
polymeric sheets 16, 18 places the tethers 36A at the
inwardly-protruding bonds 50 in tension, and the tethers 36 prevent
the tensile layers 32, 34 and polymeric sheets 16, 18 from further
outward movement away from one another. However, the tethers 36 do
not present resistance to compression when under a compressive
load. When pressure is exerted on the cushioning article 10 such as
due to a force of a dynamic impact of a wearer during running or
other movements, the cushioning article 10 is compressed, and the
polymeric sheets 16, 18 move closer together with the tethers 36
collapsing (i.e., going slack) in proportion to the pressure
exerted on the first and second polymeric sheets 16, 18 adjacent
the particular tethers 36.
Prior to bonding to the first and second polymeric sheets 16, 18
according to the method 210 disclosed herein, the tethers 36 of the
tensile component 30 may all be initial lengths, and possibly all
substantially the same length, and the first and second tensile
layers 32, 34 connected by the tethers 36 may have generally flat
outer surfaces 45, 47, respectively, directly above the tethers 36
as shown in FIG. 15. In FIG. 15, the tethers 36 are represented in
a slackened state as FIG. 15 represents the tensile component 30
prior to securement within a sealed, pressurized interior cavity
22.
Under the method 210 provided herein, although the tethers 36 are
originally of the same length and the outer surfaces 45, 47 of the
first and second tensile layers 32, 34 and the outer surfaces 49,
54 of the first and second polymeric sheets 16, 18, respectively,
are generally flat directly above the tethers 36 (i.e., not
contoured) prior to manufacture of the cushioning article 10, the
method of manufacturing 210 produces inwardly-protruding bonds 50
that join the first polymeric sheet 16 to the first tensile layer
32 that protrude from the first polymeric sheet 16 toward the
second polymeric sheet 18 directly into a region of the cavity 22
occupied by some of the tethers 36. In fact, in FIG. 3, there are
multiple inwardly-protruding bonds 50.
Each bond 50 in the first polymeric sheet 16 results from a
respective protrusion 51 of a mold component 53A (best shown in
FIGS. 15 and 18 as a plurality of protrusions 51 arranged in closed
shapes) that contacts the first polymeric sheet 16 during the
method of manufacturing 210 disclosed herein. Each bond 50 in the
second polymeric sheet 18 results from a respective protrusion 51
of a mold component 53B (also shown as a plurality of protrusions
51 arranged in closed shapes) that contacts the second polymeric
sheet 18 during the method of manufacturing 210 disclosed herein
(see FIG. 15). FIG. 18 shows a representative mold component 53A
having the protrusions 51 in a first pattern that result in the
bond pattern 55A of inwardly-protruding bonds 50 of the cushioning
article 10 shown in FIG. 1. The mold component 53B is identical to
mold component 53A, and results in the same bond pattern 55A on the
second polymeric sheet 18. The mold component 53A is a first mold
insert, and may also be referred to as a shim. The mold component
53B is a second mold insert. The bonds 50 are indicated with hidden
lines in FIGS. 1 and 2 as they protrude inward from the outer
surfaces 49, 54 shown.
The bonds 50 result in depressed grooves 52 at the outer surface 49
of the first polymeric sheet 16 and at the outer surface 54 of the
second polymeric sheet 18. Only some of the bonds 50 and some of
the grooves 52 are indicated in FIGS. 1 and 2 for clarity. As best
shown in FIGS. 1 and 2, the inwardly-protruding bonds 50 on the
first polymeric sheet 16 define closed shapes surrounding portions
of the first polymeric sheet 16. The inwardly-protruding bonds 50
on the second polymeric sheet 18 define closed shapes surrounding
portions of the second polymeric sheet 18. In the embodiment shown,
the closed shapes are polygons. For example, one closed shape is a
pentagon, and is indicated in FIG. 1 by numbering the bonds 50 that
surround and define the closed shape as bonds 50A, 50B, 50C, 50D,
and 50E. The corresponding grooves 52 are numbered as 52A, 52B,
52C, 52D, and 52E.
Due to the pressure of the gas in the interior cavity 22, a portion
16A of the first polymeric sheet 16 that is not bonded to the first
tensile layer 32 (i.e., unbonded) and is surrounded by the bonds
50A, 50B, 50C, 50D, 50E defining the closed shape is displaced from
the first tensile layer 32 (i.e., lifted away from the first
tensile layer) such that the portion 16A of the first polymeric
sheet 16 has a domed surface 49A extending away from the first
tensile layer 32. The closed shape and domed surface 49A indicated
is only one of many closed shapes and resulting domes surfaces at
the outer surface 49 of the first polymeric sheet 16. Additional
portions with domed surfaces 49B, 49C, 49D, 49E are indicated in
FIG. 3 and may be referred to as domed portions. As is apparent
from the plan view of FIG. 1, the first polymeric sheet 16
effectively has a multitude of rounded bubble-like shapes extending
over each of the forefoot region 17A, the midfoot region 17B, and
the heel region 17C of the cushioning article 10. As used herein,
"domed" means rounded, and need not be hemispherical.
Similarly, with reference to FIG. 2, one closed shape at the second
polymeric sheet 18 is a pentagon, indicated in FIG. 2 by numbering
the bonds 50 that surround and define the closed shape as bonds
50F, 50G, 50H, 50I, and 50J. The corresponding grooves 52 are
numbered as 52F, 52G, 52H, 52I, and 52J. Due to the pressure of the
gas in the interior cavity 22, a portion 18A of the second
polymeric sheet 18 surrounded by the bonds 50F, 50G, 50H, 50I, 50J
defining the closed shape is displaced from the second tensile
layer 34 such that the portion 18A of the second polymeric sheet 18
has a domed surface 54A extending away from the second tensile
layer 34 as best shown in FIG. 3. The closed shape and portion of
second polymeric sheet 18 with a domed surface 54A indicated is
only one of many closed shapes and resulting portions with domes
surfaces at the outer surface 54 of the second polymeric sheet 18.
Additional portions with domed surfaces 54B, 54C, 54D, 54E are
indicated in FIG. 3. As is apparent from the bottom view of FIG. 2,
the second polymeric sheet 18 effectively has a multitude of
rounded, bubble-like shapes extending over each of the forefoot
region 17A, the midfoot region 17B, and the heel region 17C of the
cushioning article 10.
Each inwardly-protruding bond 50 partially traverses the plurality
of tethers 36 as shown in FIG. 3. Stated differently, the bonds 50
are directly outward of different ones of the tethers 36 and
protrude inward on those tethers 36. The tethers 36 may be arranged
in rows, with each row extending transversely between the tensile
layers 32, 34, or in any other pattern in which the tethers 36
extend between the tensile layers 32, 34. Various different ones of
the tethers 36 are aligned with the bonds 50. An
inwardly-protruding bond 50 may traverse different rows of the
tethers 36 such that different tethers from different rows are
aligned with an inwardly-protruding bond 50, or an
inwardly-protruding bond 50 may be directly aligned with a single
row. Some of the inwardly-protruding bonds 50 could be between rows
of tethers.
With reference to FIG. 4, the plurality of tethers 36 includes
tethers 36A aligned with the inwardly-protruding bonds 50 and
tethers 36B displaced from the inwardly-protruding bonds 50.
Tethers 36A that are aligned with an inwardly-protruding bonds 50
are deformed by heat, by compression of the overlaying materials of
the first tensile layer 32 and the second tensile layer 34, and/or
by the overlaying material of the first tensile layer 32 and/or the
second tensile layer 34 coating the tethers 36A such that the
tethers 36A are shorter, thicker, or both shorter and thicker at
the inwardly-protruding bonds 50 than elsewhere. Such tethers are
indicated with reference numeral 36A in FIG. 4 and may be referred
to as modified tethers 36A. However, references to tethers 36
herein include tethers 36A and tethers 36B unless otherwise
specified.
When the interior cavity 22 is inflated, the modified tethers 36A
result in depressed grooves 52 in the outer surface 49 of the first
polymeric sheet 16, as indicated in FIG. 3. When an inflation
pressure of the gas in the interior cavity 22 against the inner
surfaces of the polymeric sheets 16, 18 is sufficient to cause the
polymeric sheets 16, 18 to tension the tethers 36A, the
inwardly-protruding bonds 50 define the grooves 52 at the outer
surface 49 of the first polymeric sheet 16 and in the outer surface
54 of the second polymeric sheet 18. At each groove 52, the
cushioning article 10 is divided into what may be referred to as a
first article portion 61 on one side of the groove 52 and a second
article portion 62 on the other side of the groove 52, as indicated
in FIG. 4 with respect to the left-most groove 52 indicated. The
first article portion 61 is articulated relative to the second
article portion 62 along the groove 52. Stated differently, the
outer surface 49 of the first polymeric sheet 16 at a first side of
the inwardly-protruding bond 50 (the first side indicated in FIG. 4
as portion 49D of outer surface 49) is non-planar with the outer
surface 49 of the first polymeric sheet 16 at a second side of the
inwardly-protruding bond 50 (the second side indicated in FIG. 4 as
portion 49C of outer surface 49), with the second side opposite of
the first side. The outer surface 54 of the second polymeric sheet
18 at a first side of the inwardly-protruding bond 50 (the first
side indicated in FIG. 4 as portion 54D of outer surface 54) is
non-planar with the outer surface 54 of the second polymeric sheet
18 at a second side of the inwardly-protruding bond 50 (the second
side indicated in FIG. 4 as portion 54C of outer surface 54), with
the second side opposite of the first side.
The grooves 52 may act as flexion axes of the cushioning article
10. For example, when the cushioning article 10 is included in the
sole structure 12 of the article of footwear 14 in FIG. 9, the
inwardly-protruding bonds 50 and resulting grooves 52 may establish
flexion axes of the sole structure 12. The bonds 50 may be
configured so that many of the bonds 50 fall lengthwise near or
along a common axis to establish flexion axes that may align with
joints of the foot, such as the metatarsal phalangeal joints,
thereby increasing flexibility of the sole structure 12. Various
flexion axes F1, F2 are indicated in FIG. 1. Flexion axes increase
flexibility of the cushioning article 10. In some embodiments, some
of the bonds 50 may be aligned in a straight line from the medial
side to the lateral side of the cushioning article, creating a
flexion axis that extends transversely across the entire cushioning
article.
Referring to FIGS. 3 and 4, each inwardly-protruding bond 50 at the
first polymeric sheet 16 is spaced apart from the second polymeric
sheet 18, and each inwardly-protruding bond 50 at the second
polymeric sheet 18 is spaced apart from the first polymeric sheet
16 such that the interior cavity 22 is narrowed but not closed at
the inwardly-protruding bonds 50. Gas in the interior cavity 22 can
thus fluidly communicate across any of the inwardly-protruding
bonds 50 (i.e., between a bond 50 on the first polymeric sheet 16
and a corresponding bond 50 on the second polymeric sheet 18). As
shown in FIG. 4, the first tensile layer 32 is spaced apart from
the second tensile layer 34 by a first distance D1 at a location
adjacent to the inwardly-protruding bond 50, and the
inwardly-protruding bond 50 at the first polymeric sheet 16 and the
first tensile layer 32 is spaced apart from the inwardly-protruding
bond 50 at the second polymeric sheet 18 and the second tensile
layer 34 by a second distance D2. The first distance D1 may be the
distance between the tensile layers 32, 34 at the tethers 36B that
are not the modified tethers 36A. The second distance D2 may be the
minimum distance between the corresponding inwardly-protruding
bonds 50 at the modified tethers 36A (i.e., the distance at the
most narrowed portion of the interior cavity 22 between
corresponding bonds 50 of the first and second polymeric sheets 16,
18). In an embodiment, the method of manufacturing 210 may be
controlled so that the second distance D2 is between 50 percent and
80 percent of the first distance D1. Bonds 50 in this range of
depth may create the most desirable amount of articulation. For
example, factors that may influence the bond 50 and the extent of
its protrusion toward the opposite first or second polymeric sheet
16, 18 can be controlled to provide this desired ratio of the
second distance D2 to the first distance D1. Such factors may
include the depth of the protrusion 51 that creates the bond 50,
the temperature of the mold insert 53 or other mold components, the
temperature of the components of the cushioning article 10, vacuum
and/or inflation pressures in the mold cavity during manufacturing,
the power of weld frequency if radio frequency welding is used, and
other factors.
Accordingly, a portion 22A of the interior cavity 22 at a first
side of corresponding inwardly-protruding bonds 50 is in fluid
communication with a portion 22B of the interior cavity 22 at a
second side of the corresponding inwardly-protruding bonds 50, with
the second side opposite of the first side, as indicated in FIG. 4.
The modified tethers 36A shown extending under the corresponding
bonds 50 between the two portions 22A, 22B are narrow in diameter
and allow gas to flow around and between the tethers 36A from the
portion 22A to the portion 22B and vice versa. This allows the gas
to be displaced from the portion 22A to the portion 22B and from
portion 22B to portion 22A when compressive forces are applied to
the cushioning article 10, such as during impact of the article of
footwear 14 with the ground Gin FIG. 9. For example, as a foot
rolls forward from heel to toe during a foot strike, the gas may be
displaced from rearward in the cushioning article 10 to a portion
more forward in the cushioning article 10. Supportive cushioning
provided by the interior cavity 22 can thus be provided in areas
most needed during use of the cushioning article 10.
FIGS. 5-7 show stages of compression of the cushioning article 10
under compressive force F applied normal to the domed surfaces of
the first and second polymeric sheets 16, 18, such as under dynamic
compressive loading during a foot strike when the cushioning
article is a sole component of the sole structure 12 of FIG. 9.
During initial loading, the portions with domed surfaces 49B, 49C,
49D and 54B, 54C, 54D begin to flatten, and the gas in the interior
cavity 22 becomes more pressurized as the volume of the cavity 22
decreases, as depicted by the changes to the cushioning article 10
from FIG. 5 to FIG. 6. Under continued loading, the domed surfaces
may completely flatten, and the first and second polymeric sheets
16, 18 contact the first and second tensile components 32, 34
between the bonds 50. With even further loading the shortened
tethers 36A will collapse. When the dynamic compressive forces F
are removed, the tethers 36A will return to a tensioned state, and
the portions of the first and second polymeric sheets 16, 18
between the closed shapes of the bonds 50 will return to their
domed shapes.
FIGS. 10-11 show another embodiment of a cushioning article 110.
The cushioning article 110 has many of the same features as
cushioning article 10, and these are shown with like reference
numbers and are as described with respect to the cushioning article
10. The sheets 16, 18 form a bladder 123, with the first polymeric
sheet establishing the proximal side of the bladder 123 and the
second polymeric sheet 18 establishing the distal side of the
bladder 123. In the cushioning article 110, anti-weld material is
applied only forward of a representative dividing line 113 on the
first and second polymeric sheets 16, 18 and/or on the tensile
layers 32, 34 where bonding is not desired. Accordingly, as
indicated in FIGS. 12 and 14, the first and second polymeric sheets
16, 18 have portions with inner surfaces 42, 46 that are surrounded
by a first plurality of bonds 50 arranged in closed shapes, and are
displaced from the outer surfaces 45, 47 of the adjacent first and
second tensile layers 32, 34, respectively, forming the domed
surfaces 49F, 49G, 54F, 54G, etc., only in a first region of the
first polymeric sheet 16, which is the region forward of the
dividing line 113.
In a second region of the first polymeric sheet 16, which is a
region rearward of the dividing line 113 in FIGS. 10, 11, 12, and
14, the inner surface 42 of the first polymeric sheet 16 is bonded
to an outer surface 45 of the first tensile layer 32 at surface
bonds 40, and the inner surface 46 of the second polymeric sheet 18
is bonded to the outer surface 47 of the second tensile layer 34 at
surface bonds 44. A mold is used so that protrusions 51 contact the
only first polymeric sheet 16 in the second region. A second
plurality of inwardly-protruding bonds 50 arranged in closed shapes
are formed at the first polymeric sheet 16 in the second region,
but not in the second polymeric sheet 18 in the second region. When
the interior cavity 22 is inflated, the modified tethers 36A result
in depressed grooves 52 in the outer surface 49 of the first
polymeric sheet 16 and in the outer surface 54 of the second
polymeric sheet 18 at the inwardly-protruding bonds 50. When an
inflation pressure of the gas in the interior cavity 22 is
sufficient to tension the plurality of tethers 36A at the
inwardly-protruding bonds 50, the inwardly-protruding bonds 50
define grooves 52 at the outer surface 49 of the first polymeric
sheet 16 and at the outer surface 54 of the second polymeric sheet
18. Although the first and the second pluralities of bonds 50 are
shown on the first polymeric sheet 16 on the proximal side, the
cushioning article 110 could be used in an article of footwear with
the first polymeric sheet on the distal side.
The tension of the modified tethers 36A also causes recesses 56 in
the outer surface 54 of the second polymeric sheet 18 opposite each
of the inwardly-protruding bonds 50 of the first polymeric sheet
16. The second polymeric sheet 18 is recessed inward toward a
corresponding groove 52 and inwardly-protruding bond 50 at each
recess 56 when the interior cavity 22 is inflated. The grooves 52
are generally deeper than the recesses 56, which may cause the
cushioning article 10 to be articulated in the second region even
when not under a compressive load, as the cushioning article 10
curves slightly upward at each groove 52. Stated differently, the
physical deformation of the first polymeric sheet 16 and the first
tensile layer 32 combined with the tension of the modified tethers
36A will cause the grooves 52 to be deeper than the recesses 56,
which result only from the tension of the shortened modified
tethers 36A. Accordingly, the second region of the cushioning
article 10 may have an articulated shape, such as when not under
loading at the grooves 52, as shown in FIG. 14, where the second
region is slightly curved upward from the horizontal line H.
Additionally, the grooves 52 and recesses 56 together encourage
articulation of the cushioning article 10 to occur at the grooves
52, as the overall thickness of the cushioning article 10 is
reduced at the grooves 52, decreasing bending stiffness of the
cushioning article at the grooves 52. In contrast, the cushioning
article 10 that has grooves 52 on both sides due to
inwardly-protruding bonds 50 at both the first and second polymeric
sheets 16, 18 remains more level and less articulated than the
cushioning article 110 when not under loading, but, like cushioning
article 110, encourages articulation at the grooves 52.
Due to the surface bonds 40, any rounding or doming of the
polymeric sheet 16 at the closed shapes surrounded by
inwardly-protruding bonds 50 is lessened, and does not include any
displacement of the first polymeric sheet 16 from the first tensile
layer 32. In FIG. 14, the first and second tensile layers 32, 34
are indicated with hidden lines following the contours of the first
and second polymeric sheets 16, 18 in the second region, and are
intended to indicate that the inner surfaces 42, 46 are bonded to
the outer surfaces 45, 47 in the entirety of the second region. As
shown in FIG. 12, at a first inwardly-protruding bond 50K, the
interior cavity 22 is narrowed but not closed, so gas can
communicate across the bond 50K and the corresponding bond 50 of
the second polymeric sheet 18. At a second inwardly-protruding bond
50L in the second region, the interior cavity 22 is narrowed but
not closed, so gas can communicate across the bond 50L and a
corresponding bond 50 of the second polymeric sheet 18.
FIG. 15 shows the components of the cushioning article 10 in an
exploded view and positioned between components of a mold 66. More
specifically, the components of mold 66 (also referred to herein as
mold components) include a first mold portion 66A, a second mold
portion 66B, a first mold insert 53A, and a second mold insert 53B.
The components of the mold necessary to manufacture the cushioning
article 110 are the same except that the second mold insert 53B
would not have protrusions 51 as no inwardly-protruding bonds are
created at the second polymeric sheet 18 in the cushioning article
110. Alternatively, the second mold portion 66B could be modified
so that no mold insert is necessary, and the mold surface
contacting the outer surface 54 of the second polymeric sheet 18
has no protrusions 51. FIG. 16 shows the components of the
cushioning article 10 in a mold cavity 68 of the mold 66 defined by
the mold components with the mold 66 in a closed position. Although
the polymeric sheets 16, 18 are in contact with the tensile
components 32, 34 in the mold 66, anti-weld material prevents
bonding of the polymeric sheets 16, 18 to the tensile components
32, 34 where the anti-weld material is disposed.
FIGS. 21-24 show another embodiment of a cushioning article 310.
The cushioning article 310 has many of the same features as
cushioning articles 10 and 110, and these are shown with like
reference numbers and are as described with respect to the
cushioning article 310. In the cushioning article 310, anti-weld
material is applied to the inner surfaces of only the second
polymeric sheet 18 and/or on the tensile layer 34. Accordingly, as
indicated in FIG. 23, the first polymeric sheet 16 is at a proximal
side of the cushioning article 310 and has a plurality of bonds 50
(referred to as a second plurality of bonds) in a second region of
the bladder 323 which is the entire forefoot region 17A, midfoot
region 17B, and heel region 17C on a distal side of the bladder 323
(defining closed shapes, and portions surrounded by the closed
shapes having surface bonds 40 to the first tensile layer 32. The
second polymeric sheet 18 has portions with a first plurality of
bonds 50 arranged in closed shapes surrounding portions with inner
surfaces 46 that are displaced from the outer surface 47 of the
adjacent second tensile layer 34, forming the domed surfaces 54F,
54G, 54H, 54I, 54J, etc., in a first region of the second polymeric
sheet 18, which is the entire forefoot region 17A, midfoot region
17B, and heel region 17C on a distal side of the bladder 23.
In a second region of the first polymeric sheet 16, which is a
region rearward of the dividing line 113 in FIGS. 10, 11, 12, and
14, the inner surface 42 of the first polymeric sheet 16 is bonded
to an outer surface 45 of the first tensile layer 32 at surface
bonds 40, and the inner surface 46 of the second polymeric sheet 18
is bonded to the outer surface 47 of the second tensile layer 34 at
surface bonds 44. A mold is used so that protrusions 51 contact the
only first polymeric sheet 16 in the second region.
Inwardly-protruding bonds 50 are formed at the first polymeric
sheet 16 in the second region, but not in the second polymeric
sheet 18 in the second region. When the interior cavity 22 is
inflated, the modified tethers 36A result in depressed grooves 52
in the outer surface 49 of the first polymeric sheet 16 and in the
outer surface 54 of the second polymeric sheet 18 at the
inwardly-protruding bonds 50. When an inflation pressure of the gas
in the interior cavity 22 is sufficient to tension the plurality of
tethers 36A at the inwardly-protruding bonds 50, the
inwardly-protruding bonds 50 define grooves 52 at the outer surface
49 of the first polymeric sheet 16 and at the outer surface 54 of
the second polymeric sheet 18.
A method 210 of manufacturing a cushioning article, such as
cushioning article 10, 110, or 310 is shown in the flow chart of
FIG. 20, and is described with reference to FIGS. 15 and 16. The
method 210 may begin with block 211, disposing anti-weld material
on the inner surface of the first polymeric sheet 16, or on the
outer surface of the first tensile layer 32. In manufacturing the
cushioning article 110, the anti-weld material would only be
disposed forward of the dividing line 113, such as in the first
region of the first polymeric sheet 16. In manufacturing the
cushioning article 10, the method also includes block 212,
disposing anti-weld material on the inner surface of the second
polymeric sheet 18 or on the outer surface of the second tensile
layer 34. In manufacturing cushioning article 110, block 212 may be
omitted for some regions of the polymeric sheet 18 as discussed
herein. In manufacturing cushioning article 310, block 211 may be
omitted. The anti-weld material disposed in blocks 211 and 212 is
not disposed in locations where bonds 50 are desired. For example,
the anti-weld material may be disposed forward of dividing line 113
as described, but avoiding the areas of the sheets 16, 18 and the
tensile layers 32, 34 where bonds are desired. The correct
placement of anti-weld material to achieve this may be by ink-jet
printing the correct pattern on the surfaces of the sheets 16, 18
and/or tensile layers. Alternatively, the anti-weld material may be
disposed at locations where bonds are desired, if it is not
activated at those locations.
In block 213, a first mold insert 53A with a first protrusion
pattern 55A (i.e., the pattern of protrusions 51 arranged in closed
shapes) is secured to the first mold portion 66A, as best shown in
FIG. 18. For example, as indicated in FIG. 15, the first mold
insert 53A has openings 70 that receive fasteners 72. The fasteners
72 extend into openings 74 in the first mold portion 66A to secure
the first mold insert 53A to the first mold portion 66A. The
openings 74 are in a recess 75 of the first mold portion 66A, and
the mold insert 53A fits within the recess 75 so that the surface
76 is flush with adjacent surfaces 78 of the first mold portion
66A. The openings 70, 74 and the fasteners 72 may be threaded, for
example. When disposed as set forth in block 212, the mold insert
53A is therefore in and partially defines the mold cavity 68.
When manufacturing the cushioning article 10 or 310, a second mold
insert 53B having a plurality of protrusions 51 arranged in closed
shapes will be secured to the second mold portion 66B in block 214
in the same manner as first mold insert 53A is secured to first
mold portion 66A. For some configurations, the first and second
mold portions 66A, 66B may be configured with the plurality of
protrusions 51 arranged in closed shapes such that no mold inserts
53A, 53B need be used. However, the use of mold inserts 53A, 53B
allows the same mold portions 66A, 66B to be used in manufacturing
cushioning articles with different bond patterns simply by changing
either or both mold inserts 53A, 53B for those with an alternative
pattern of protrusions. When manufacturing the cushioning article
110, no protrusions are necessary adjacent the second polymeric
sheet 18 rearward of line 113 as no inwardly-protruding bonds 50
are created in the second polymeric sheet 18 in this region.
Accordingly, in manufacturing the cushioning article 110, the
second mold portion 66B configured to align rearward of line 113
may be provided without protrusions and with a surface configured
to shape the outer surface of the second polymeric sheet 18.
Next, in block 215, prior to disposing the components of the
cushioning article 10 into the open mold cavity 68, the components
of the cushioning article 10 (or cushioning article 110 or 310),
the mold components 53A, 53B, 66A, 66B, or both, may be pre-heated
to help expedite the subsequent thermoforming that occurs via the
combined blocks 218, 220.
In block 216, the first and second polymeric sheets 16, 18 and the
tensile component 30 are then disposed in the mold cavity 68, with
the first tensile layer 32 positioned adjacent the first polymeric
sheet 16, the second tensile layer 34 positioned adjacent the
second polymeric sheet 18, and the plurality of tethers 36
connecting the first tensile layer to the second tensile layer.
Block 216 may comprise placing first and second polymeric sheets
16, 18 and the tensile component 30 between the open mold portions
66A, 66B. This may be accomplished by the use of shuttle frames
(not shown) that separately hold the various components of the
cushioning article 10, 110, or 310 in alignment with one another
and with the mold components 66A, 66B, 53A, 53B, as shown in FIG.
15. When manufacturing the cushioning article 110, the first and
second polymeric sheets 16, 18 may already by bonded to the
respective tensile layers 32, 34 of the tensile component 30
rearward of the dividing line 113 when placed in the mold cavity
68, such as by lamination or by the use of adhesive. Alternatively,
as shown in FIG. 15, the first and second polymeric sheets 16, 18
may not yet be bonded to the tensile component 30. Once the
components of the cushioning article 10, 110, or 310 are positioned
in the mold cavity 68, one or both of the mold components 66A, 66B
is translated toward the other mold component to close the mold
cavity 68.
Next, in block 218, the first polymeric sheet 16 and the second
polymeric sheet 18 are conformed to components of the mold 66, as
shown in FIG. 16. For example, the outer surface 49 of the first
polymeric sheet 16 is conformed to the surface 76 of the mold
insert 53A. The surface 76 includes the plurality of protrusions
51. Portions of the outer surface 49 of the first polymeric sheet
16 are conformed directly to the mold surface 78 of the first mold
portion 66A adjacent to the first mold insert 53A. Conforming of
the first polymeric sheet 16 to the surface 76, including the
plurality of protrusions 51, depresses the first polymeric sheet 16
toward the second polymeric sheet 18 at the plurality of
protrusions 51, with the plurality of protrusions 51 directly
outward of some of the plurality of tethers 36. In block 218, the
outer surface 54 of the second polymeric sheet 18 is also conformed
to the surface 77 of the second mold insert 53B and to the mold
surface 79 of the second mold portion 66B adjacent to the second
mold insert 53B, indicated in FIG. 16. Conforming the polymeric
sheets 16, 18 to the surfaces of the mold inserts 53A, 53B and the
mold portions 66A, 66B may include applying a vacuum to the mold
cavity 68 to pull the polymeric sheets 16, 18 against the surfaces
76, 77, 78, 79. Alternatively or in addition, conforming the
polymeric sheets 16, 18 to the surfaces may include pressurizing
the mold cavity 68, thereby compressing the polymeric sheets 16, 18
against the surfaces 76, 77, 78, 79.
After or contemporaneously with the first and second polymeric
sheets 16, 18 conforming to the surfaces 76, 77, 78, 79 in block
218, the first tensile layer 32 may be thermally bonded to the
first polymeric sheet 16 and the second tensile layer 34 may be
thermally bonded to the second polymeric sheet 18 opposite the
first tensile layer 32 in block 220. The heating of the polymeric
sheets 16, 18, the tensile layers 32, 34, and/or the mold
components 53A, 53B, 66A, 66B in addition to the vacuum and/or
pressurization of the mold cavity 68 enables the thermal bonding at
the surface bonds 40, 44 and the inwardly-protruding bonds 50. When
the components of the cushioning article 10 are cooled, the bonds
40, 44, 50 remain. Conforming in block 218 and thermally bonding in
block 220 may be referred to as thermoforming, and produces the
inwardly-protruding bonds 50 at the protrusions 51 that join the
first polymeric sheet 16 and the first tensile layer 32 and
partially traverse the plurality of tethers 36, with the
inwardly-protruding bonds 50 protruding toward the second polymeric
sheet 18 but remaining spaced apart from the second tensile layer
34 and the second polymeric sheet 18 as described with respect to
FIG. 3.
The thermal bonding of block 220 may include heating the first
polymeric sheet 16 and the second polymeric sheet 18 prior to
disposing the first polymeric sheet 16 and the second polymeric
sheet 18 in the mold cavity 68. Alternatively or in addition, the
thermal bonding may include heating one or more of the mold
components 53A, 53B, 66A, 66B, or radio frequency welding via the
mold 66.
Following block 220 or contemporaneously with block 220, the method
210 may include block 222, bonding the first polymeric sheet 16 to
the second polymeric sheet 18 at the peripheral bond 20 such that
the first polymeric sheet 16 and the second polymeric sheet 18 at
least partially enclose the interior cavity 22 containing the
tensile component 30. For example, bonding the first polymeric
sheet 16 and the second polymeric sheet 18 at the peripheral bond
20 in block 222 may include compressing the first polymeric sheet
16 and the second polymeric sheet 18 between the first mold portion
66A and the second mold portion 66B in the closed position, as
shown in FIG. 16. A small portion of the periphery of the first and
second polymeric sheets 16, 18 can be left unbonded, such as at an
inflation port 82 molded into the sheets in blocks 218 and 220.
After block 222, the mold cavity 68 may be opened in block 224 by
translating one or both of the mold portions 66A, 66B away from one
another. The cushioning article 10 can then be removed from the
mold cavity 68 in block 226.
In block 228, the interior cavity 22 can be inflated to a desired
inflation pressure, such as through the inflation port 82 of FIG.
1. For example, a fill tube may fit into the inflation port 82 or
may be integrally formed by the sheets 16, 18 at the inflation port
82. Prior to or after inflating the interior cavity 22 in block
228, excess material of the sheets 16, 18 around the peripheral
bond 20 can be trimmed. Gas, such as air, can be dispensed from a
pressurized source or pumped into the interior cavity 22 through
the inflation port 82 from a pressurized source. In some
embodiments, the interior cavity 22 is not inflated, but instead
simply retains gas at atmospheric pressure.
The interior cavity 22 is sealed in block 230. In the embodiment
shown, this may be accomplished by sealing the inflation port 82,
such as by thermally bonding the sheets 16, 18 to one another at
the inflation port 82, adhering the sheets 16, 18 to one another at
the inflation port 82, or plugging the inflation port 82. In FIG.
1, the sheets 16, 18 and any fill tube is already trimmed, and the
inflation port 82 is sealed. The cushioning article 10, 110, or 310
is completely manufactured once block 230 is completed, and is
ready to be assembled in the article of footwear 14. If the
interior cavity 22 is inflated to a sufficient pressure, portions
of the polymeric sheet 16 and/or 18 of the cushioning article 10,
110, or 310 that forms domed portions with domed surfaces 49A-49D,
54A-54J, etc., and the plurality of tethers 36A at the bonds 50 are
tensioned, creating the grooves 52 in the outer surface 49 of the
first polymeric sheet 16 and at the outer surface 54 of the second
polymeric sheet 18 at the inwardly-protruding bonds 50, thereby
articulating the cushioning article 10, 110, or 310 as discussed
with respect to FIG. 6, with the grooves 52 establishing flexion
axes.
It should be appreciated that, although in FIGS. 15-16 the mold
component having the protrusions 51 that create the
inwardly-protruding bonds 50 is a mold insert 53A and/or 53B,
either or both of the mold portions 66A, 66B could have one or more
protrusions, and no mold insert need be used. However, the use of
mold inserts may allow the production of cushioning articles having
different bond patterns with lower tooling expense. For example,
the same mold portions 66A, 66B may be used with a different
tooling insert having a different pattern of protrusions to produce
cushioning articles with different bond patterns. For example, FIG.
19 shows a different mold insert 53AA with a different pattern 55AA
of protrusions 51. The protrusions 51 of the mold insert 53AA are
shaped, dimensioned, or positioned differently than the protrusions
51 of the first mold insert 53A such that the pattern of
protrusions 51 of mold insert 53AA is different than the first
pattern of protrusions of mold insert 53A.
After manufacturing the cushioning article having a first bond
pattern (i.e., a first pattern of inwardly-protruding bonds
corresponding to the first pattern of protrusions of the first mold
insert 53A), the method 210 may include block 232, removing the
first mold insert 53A from the mold cavity 68. Then, in block 234,
the different mold insert 53AA may be secured to the mold portion
66A, using fasteners 72 extending through openings 70, 74 as
described with respect to the mold insert 53A. Mold insert 53B may
also be replaced with a different mold insert with a different
pattern of protrusions. With the mold insert 53AA now disposed in
the mold cavity 68, and potentially a different mold insert secured
to mold portion 66B and disposed in the cavity 68, blocks 211 to
230 of the method 210 can now be repeated to manufacture a second
cushioning article that is a full length sole component having a
different bond pattern than the first full length sole component
produced using mold inserts 53A, 53B the different bond pattern
being a pattern of inwardly-protruding bonds 50 as described
herein, but corresponding to the different pattern of protrusions
of the different mold insert 53AA, for example.
For example, in repeating blocks 211 to 230, block 216 is repeated
by disposing a subsequent first polymeric sheet 16, a subsequent
second polymeric sheet 18, and a subsequent tensile component 30 in
the mold cavity 68 with the subsequent tensile component between
the subsequent first polymeric sheet and the subsequent second
polymeric sheet. Block 218 is repeated by conforming the subsequent
first polymeric sheet to the different mold insert 53AA and the
subsequent second polymeric sheet to a different mold insert or to
another one of the mold components (e.g., a mold component similar
to mold component 66B), respectively, the conforming depressing the
subsequent first polymeric sheet toward the subsequent second
polymeric sheet at the second protrusion 51 (i.e., at one of the
protrusions 51 of the different mold insert 53AA), with the second
protrusion directly outward of the subsequent tensile component.
For example, block 220 is repeated, thermally bonding the first
tensile layer of the subsequent tensile component to the subsequent
first polymeric sheet and the second tensile layer of the
subsequent tensile component to the subsequent second polymeric
sheet to produce a second inwardly-protruding bond 50 at the second
protrusion partially traversing the subsequent tensile component.
The same mold portions and mold cavity thus provide a second
cushioning article with a different bond pattern than the first
cushioning article due to the different mold insert 53AA, and
simply by removing the first mold insert 53A and replacing it with
the different mold insert 53AA, and, when manufacturing a
cushioning article with inwardly-protruding bonds 50 at the second
polymeric sheet 18, such as cushioning article 10, potentially
replacing the second mold insert 53B with a different mold
insert.
To assist and clarify the description of various embodiments,
various terms are defined herein. Unless otherwise indicated, the
following definitions apply throughout this specification
(including the claims). Additionally, all references referred to
are incorporated herein in their entirety.
An "article of footwear", a "footwear article of manufacture", and
"footwear" may be considered to be both a machine and a
manufacture. Assembled, ready to wear footwear articles (e.g.,
shoes, sandals, boots, etc.), as well as discrete components of
footwear articles (such as a midsole, an outsole, an upper
component, etc.) prior to final assembly into ready to wear
footwear articles, are considered and alternatively referred to
herein in either the singular or plural as "article(s) of footwear"
or "footwear".
"A", "an", "the", "at least one", and "one or more" are used
interchangeably to indicate that at least one of the items is
present. A plurality of such items may be present unless the
context clearly indicates otherwise. All numerical values of
parameters (e.g., of quantities or conditions) in this
specification, unless otherwise indicated expressly or clearly in
view of the context, including the appended claims, are to be
understood as being modified in all instances by the term "about"
whether or not "about" actually appears before the numerical value.
"About" indicates that the stated numerical value allows some
slight imprecision (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If the
imprecision provided by "about" is not otherwise understood in the
art with this ordinary meaning, then "about" as used herein
indicates at least variations that may arise from ordinary methods
of measuring and using such parameters. As used in the description
and the accompanying claims, unless stated otherwise, a value is
considered to be "approximately" equal to a stated value if it is
neither more than 5 percent greater than nor more than 5 percent
less than the stated value. In addition, a disclosure of a range is
to be understood as specifically disclosing all values and further
divided ranges within the range.
The terms "comprising", "including", and "having" are inclusive and
therefore specify the presence of stated features, steps,
operations, elements, or components, but do not preclude the
presence or addition of one or more other features, steps,
operations, elements, or components. Orders of steps, processes,
and operations may be altered when possible, and additional or
alternative steps may be employed. As used in this specification,
the term "or" includes any one and all combinations of the
associated listed items. The term "any of" is understood to include
any possible combination of referenced items, including "any one
of" the referenced items. The term "any of" is understood to
include any possible combination of referenced claims of the
appended claims, including "any one of" the referenced claims.
For consistency and convenience, directional adjectives may be
employed throughout this detailed description corresponding to the
illustrated embodiments. Those having ordinary skill in the art
will recognize that terms such as "above", "below", "upward",
"downward", "top", "bottom", etc., may be used descriptively
relative to the figures, without representing limitations on the
scope of the invention, as defined by the claims.
The term "longitudinal" refers to a direction extending a length of
a component. For example, a longitudinal direction of an article of
footwear extends between a forefoot region and a heel region of the
article of footwear. The term "forward" or "anterior" is used to
refer to the general direction from a heel region toward a forefoot
region, and the term "rearward" or "posterior" is used to refer to
the opposite direction, i.e., the direction from the forefoot
region toward the heel region. In some cases, a component may be
identified with a longitudinal axis as well as a forward and
rearward longitudinal direction along that axis. The longitudinal
direction or axis may also be referred to as an anterior-posterior
direction or axis.
The term "transverse" refers to a direction extending a width of a
component. For example, a transverse direction of an article of
footwear extends between a lateral side and a medial side of the
article of footwear. The transverse direction or axis may also be
referred to as a lateral direction or axis or a mediolateral
direction or axis.
The term "vertical" refers to a direction generally perpendicular
to both the lateral and longitudinal directions. For example, in
cases where a sole structure is planted flat on a ground surface,
the vertical direction may extend from the ground surface upward.
It will be understood that each of these directional adjectives may
be applied to individual components of a sole structure. The term
"upward" or "upwards" refers to the vertical direction pointing
towards a top of the component, which may include an instep, a
fastening region and/or a throat of an upper. The term "downward"
or "downwards" refers to the vertical direction pointing opposite
the upwards direction, toward the bottom of a component and may
generally point towards the bottom of a sole structure of an
article of footwear.
The "interior" of an article of footwear, such as a shoe, refers to
portions at the space that is occupied by a wearer's foot when the
article of footwear is worn. The "inner side" of a component refers
to the side or surface of the component that is (or will be)
oriented toward the interior of the component or article of
footwear in an assembled article of footwear. The "outer side" or
"exterior" of a component refers to the side or surface of the
component that is (or will be) oriented away from the interior of
the article of footwear in an assembled article of footwear. In
some cases, other components may be between the inner side of a
component and the interior in the assembled article of footwear.
Similarly, other components may be between an outer side of a
component and the space external to the assembled article of
footwear. Further, the terms "inward" and "inwardly" refer to the
direction toward the interior of the component or article of
footwear, such as a shoe, and the terms "outward" and "outwardly"
refer to the direction toward the exterior of the component or
article of footwear, such as the shoe. In addition, the term
"proximal" refers to a direction that is nearer a center of a
footwear component, or is closer toward a foot when the foot is
inserted in the article of footwear as it is worn by a user.
Likewise, the term "distal" refers to a relative position that is
further away from a center of the footwear component or is further
from a foot when the foot is inserted in the article of footwear as
it is worn by a user. Thus, the terms proximal and distal may be
understood to provide generally opposing terms to describe relative
spatial positions.
While various embodiments have been described, the description is
intended to be exemplary, rather than limiting and it will be
apparent to those of ordinary skill in the art that many more
embodiments and implementations are possible that are within the
scope of the embodiments. Any feature of any embodiment may be used
in combination with or substituted for any other feature or element
in any other embodiment unless specifically restricted.
Accordingly, the embodiments are not to be restricted except in
light of the attached claims and their equivalents. Also, various
modifications and changes may be made within the scope of the
attached claims.
While several modes for carrying out the many aspects of the
present teachings have been described in detail, those familiar
with the art to which these teachings relate will recognize various
alternative aspects for practicing the present teachings that are
within the scope of the appended claims. It is intended that all
matter contained in the above description or shown in the
accompanying drawings shall be interpreted as illustrative and
exemplary of the entire range of alternative embodiments that an
ordinarily skilled artisan would recognize as implied by,
structurally and/or functionally equivalent to, or otherwise
rendered obvious based upon the included content, and not as
limited solely to those explicitly depicted and/or described
embodiments.
* * * * *